Probe Assembly Spacer Segmentation for Insertion Throughput

Solution Overview

Problem

The throughput of automated probe insertion processes in probe card assembly is limited by the thickness of the dielectric spacer plate, which affects the time required for inserting probes through the assembly, and existing solutions do not efficiently balance structural stability with reduced insertion time.

Innovation Solution

A plurality of dielectric spacer plates are used, with a thinner unitary spacer plate for initial insertion and a sliding spacer plate inserted laterally to achieve the final vertical spacing, reducing the initial insertion time without compromising structural stability.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Loss of time

If a thick dielectric spacer plate is used to maintain structural stability, then the probe insertion time increases, but if a thin dielectric spacer plate is used to reduce insertion time, then structural stability is compromised

Engineering Contradiction:

Improveprobe insertion timeVSAvoidstructural stability

Core Design Contradiction:

Loss of timeVSStability of the object's composition

Solution Approach 1:

The dielectric spacer function is divided into two separate components: a thin unitary dielectric spacer plate that provides initial spacing during automated probe insertion, and a thicker sliding dielectric spacer plate that is inserted later to achieve final spacing and enhanced structural stability. This segmentation allows the insertion process to benefit from the thin plate while the final assembly benefits from the thick plate's stability.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The thin unitary dielectric spacer plate is placed in position before automated probe insertion to enable rapid initial positioning. After insertion is complete, the additional thick sliding dielectric spacer plate is then inserted to provide the final structural stability. This preliminary action with the thin plate allows the time-sensitive insertion to proceed quickly.

Inventive Principle:

Principle #10Preliminary action

2Productivity

If a thick dielectric spacer plate is used, then structural stability is maintained, but the throughput of probe insertion operations decreases

Engineering Contradiction:

Improvethroughput of probe insertion operationsVSAvoidstructural stability

Core Design Contradiction:

ProductivityVSStability of the object's composition

Solution Approach 1:

The dielectric spacer function is divided into two separate components: a thin unitary dielectric spacer plate that provides initial spacing during automated probe insertion, and a thicker sliding dielectric spacer plate that is inserted later to achieve final spacing and enhanced structural stability. This segmentation allows the insertion process to benefit from the thin plate while the final assembly benefits from the thick plate's stability.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The thin unitary dielectric spacer plate is placed in position before automated probe insertion to enable rapid initial positioning. After insertion is complete, the additional thick sliding dielectric spacer plate is then inserted to provide the final structural stability. This preliminary action with the thin plate allows the time-sensitive insertion to proceed quickly.

Inventive Principle:

Principle #10Preliminary action

3Loss of time

If a thin dielectric spacer plate is used for initial insertion, then insertion time is reduced, but additional steps are required to achieve final spacing

Engineering Contradiction:

Improveinitial insertion timeVSAvoidassembly process complexity

Core Design Contradiction:

Loss of timeVSDevice complexity

Solution Approach 1:

The dielectric spacer function is divided into two separate components: a thin unitary dielectric spacer plate that provides initial spacing during automated probe insertion, and a thicker sliding dielectric spacer plate that is inserted later to achieve final spacing and enhanced structural stability. This segmentation allows the insertion process to benefit from the thin plate while the final assembly benefits from the thick plate's stability.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The sliding dielectric spacer plate is designed to be inserted laterally after the initial probe insertion is complete, allowing the assembly process to adapt dynamically to the needs of each stage. The sliding mechanism enables the thick plate to be added without requiring repositioning of already-inserted probes, minimizing additional complexity.

Inventive Principle:

Principle #15Dynamics

Data Source

PatentUS20250102540A1Probe assembly with multiple spacers and methods of assembling the same

Publication Date: 2025.03.27 TAIWAN SEMICONDUCTOR MANUFACTURING CO LTD

AI summary

A probe assembly includes a multilayer structure including probe contact pads, an upper guide plate including an array of upper holes therethrough, a lower guide plate including an array of lower holes therethrough, a vertical stack of a plurality of dielectric spacer plates located between the upper guide plate and the lower guide plate and including a respective opening therethrough, and an array of probes attached to the probe contact pads, vertically extending through the array of upper holes and the array of lower holes, and vertically extending through the openings through the vertical stack of the plurality of dielectric spacer plates.